CN116903389B

CN116903389B - A foam ceramic building block and its preparation method and use method

Info

Publication number: CN116903389B
Application number: CN202310888363.2A
Authority: CN
Inventors: 蔡国俊; 黄峰; 梅江涛; 刘宇; 包晗; 张若豪; 许斌
Original assignee: Third Construction Co Ltd of China Construction Eighth Engineering Divison Co Ltd
Current assignee: Third Construction Co Ltd of China Construction Eighth Engineering Divison Co Ltd
Priority date: 2023-07-19
Filing date: 2023-07-19
Publication date: 2025-03-18
Anticipated expiration: 2043-07-19
Also published as: CN116903389A

Abstract

The present invention provides a foam ceramic building block and a preparation method and a use method thereof. The raw materials of the building block include: 100 parts of a main material, 5 to 20 parts of a pore-forming agent, and 5 to 10 parts of a filler. Tap water tail mud, aluminum ash, flue ash and sulfuric acid slag are ground into powder as the main material, at least one of boron mud, carbide slag and industrial salt mud is dried and ground into powder as a pore-forming agent, at least one of pine nuts, castor beans and Spartina alterniflora powder is crushed as a filler, the above raw materials are mixed to form embryos, calcined and cooled to obtain building blocks. The foam ceramic building blocks prepared by the present invention are adhered to each other by applying a masonry agent. The foam ceramic building block has the characteristics of strong mechanical properties, good thermal insulation effect and excellent sound absorption capacity, and is of great significance in the fields of improving the comprehensive utilization rate of solid waste and developing energy-saving building materials.

Description

Foam ceramic building block and preparation method and application method thereof

Technical Field

The invention relates to the technical field of building materials, and further relates to the technical field of building blocks, in particular to a foam ceramic building block, a preparation method and a use method thereof.

Background

With the rapid development of economy and the continuous improvement of production processes, the types and the amounts of solid wastes produced are also rising year by year. The traditional incineration, landfill and other treatment modes not only occupy a large amount of land, but also form serious threat to the local ecological environment and the life and property safety of residents. The exploration of recycling the solid wastes to be used for economic construction has important practical significance.

Modern economic construction makes the contradiction between energy and environment increasingly worse. The current building energy consumption accounts for about 30% of the total global energy consumption, and the CO ₂ emitted by the building energy accounts for more than 1/3 of the total global emission. Through developing the building energy-saving material with low cost and environmental protection, the energy consumption and the carbon emission can be effectively reduced.

The ceramic foam material is a porous material with pore sizes varying from nano-scale to micro-scale. The foamed ceramic body has a large number of mutually communicated and closed pores, has the advantages of low density, low thermal shock resistance, low heat conductivity coefficient, low dielectric constant, high-temperature stability and the like, and can be widely applied to the aspects of catalysts, filtration, heat insulation materials, biological implant materials and the like.

However, the heat preservation and strength of the foam ceramic materials in the market at present are not ideal enough, and further improvement is needed.

Disclosure of Invention

Aiming at the prior art, the invention provides a foam ceramic block and a preparation method and a use method thereof in order to improve the strength, heat preservation and other effects of the ceramic block.

The invention provides a foamed ceramic block which comprises, by weight, 100 parts of a main material, 5-20 parts of a pore-forming agent and 5-10 parts of a filler, wherein the main material comprises 10-70 parts of tap water tail mud, 10-30 parts of aluminum ash, 10-30 parts of flue ash and 10-30 parts of sulfate slag.

Preferably, the pore-forming agent is at least one of boron mud, carbide slag and industrial salt mud.

In the technical scheme, the components in the boron mud, the carbide slag and the industrial salt mud are decomposed by heating to generate volatile gas, and meanwhile, the boron mud, the carbide slag and the industrial salt mud react with MgO, alumina, ferric oxide and other substances contained in raw materials to generate aluminum hydroxide, magnesium hydroxide, ferric hydroxide and other substances, and the substances are decomposed by heating to generate vapor to evaporate to form a pore channel. The components cooperatively improve the heat preservation performance of the foamed ceramic material. The foam ceramic material also needs to meet the strength requirement in industrial application, so that the product has good heat preservation performance and porosity while ensuring the strength by controlling the dosage of each component.

On the other hand, sulfur-containing substances in the sulfuric acid residues react with calcium-containing substances in boric sludge, carbide slag and industrial salt sludge to form gypsum-like substances containing calcium sulfate, and the gypsum-like substances are heated to decompose to form sulfur-containing gases, so that pore channels are formed. The cooperation of the sulfuric acid slag, the boric sludge, the carbide slag and the industrial salt mud can improve the heat preservation performance of the ceramic material.

In addition, industrial brine sludge contains sodium salt, and is reacted with raw materials to generate sodium carbonate, and is heated to generate CO ₂ gas. The gas overflows to form pores in the building block, so that the porosity is improved, and the heat preservation effect of the foamed ceramic building block is further improved.

The higher the stress, the tighter the raw materials are, and the more compact the ceramic body is formed, and the higher the strength is, so the stress is selected to be 15-20 MPa.

Preferably, the filling material is at least one of pine nut, castor bean and spartina alterniflora powder. The filler can increase the porosity and improve the heat preservation performance, but has negative influence on the strength, so the dosage is controlled to be 5-10 parts.

The invention also provides a preparation method of the foam ceramic block, which comprises the following steps:

S1, drying tap water tail mud, aluminum ash, flue ash and sulfate slag, and grinding to form a main material with fineness of 100-300 meshes;

s2, drying and grinding at least one of boron sludge, carbide slag and industrial salt sludge to form a pore-forming agent with fineness of 50-100 meshes;

S3, cleaning at least one of pine nuts, castor beans and spartina alterniflora powder, naturally air-drying, and grinding to form a filler with the average length of 1-3 mm;

S4, uniformly mixing the obtained main material, pore-forming agent and filling material according to a designed proportion, and filling the mixture into a test die to form a blank body through 15-20 MPa stress;

And S5, calcining the prepared green body, heating to 1000-1500 ℃, preserving heat for 5-10 hours, and naturally cooling to form the foamed ceramic block.

The invention further provides a using method of the foam ceramic building blocks, and the foam ceramic building blocks are adhered to each other by using a smearing masonry agent.

Preferably, the masonry agent comprises the following raw materials, by weight, 70-90 parts of a plant extractant, 10-30 parts of a solid reinforcing agent and 10-20 parts of industrial alcohol; the preparation method of the masonry agent comprises the steps of adding industrial alcohol into a plant extractant to form a solution, and then mixing the solution with a solid reinforcing agent to prepare the masonry agent.

In the technical scheme, the industrial alcohol, the plant extractant and the solid reinforcing agent cooperate with each other, so that the viscosity and the strength are ensured, the solidification time is ensured not to be too fast, and the product quality of the masonry agent is further improved. The plant extractant produces lignin and cellulose adhesive, the solid enhancer produces C-S-H gel, namely hydrated calcium silicate gel, and ethanol in industrial alcohol can break the connection bond between colloid molecules produced by the plant extractant and the solid enhancer to block molding. In addition, the ethanol is relatively volatile, only plays a blocking role in a short time, the later strength of the masonry agent is not affected, and the industrial alcohol is low in price and low in cost.

Preferably, the plant extractant comprises, by weight, 5-10 parts of hedera helix, 5-10 parts of oleander, 5-10 parts of buddleia, 20-30 parts of camphor leaves, 20-30 parts of broussonetia papyrifera leaves and 20-25 parts of humifuse euphorbia herb.

Preferably, the plant extractant is prepared by cleaning Hedera helix, oleander, buddleia, cinnamomum camphora leaf, broussonetia papyrifera leaf and herba Euphorbiae Humifusae, drying, cutting, mixing uniformly, adding equal mass water, boiling, and making into extract.

Preferably, the solid reinforcing agent comprises, by weight, 5-10 parts of phosphogypsum, 10-15 parts of quicklime, 35-55 parts of steel slag and 20-50 parts of desulfurized fly ash.

Preferably, the preparation method of the solid reinforcing agent comprises the following steps:

S1, drying and grinding desulfurization ash and steel slag into first powder with 50-100 meshes;

S2, drying phosphogypsum and quicklime and grinding into second powder with 100-200 meshes;

s3, uniformly mixing the first powder body and the second powder body to prepare the solid reinforcing agent.

Compared with the prior art, the invention has the beneficial effects that:

1. The foamed ceramic block provided by the invention takes tap water tail mud, aluminum ash, flue ash and sulfuric acid slag as main raw materials, at least one of boron mud, carbide slag and industrial salt mud as a pore-forming agent, and at least one of pine nut, castor bean and spartina alterniflora powder as a filling material. The foam ceramic block has the characteristics of strong mechanical property, good heat preservation and insulation effect, excellent sound absorption capability and the like, and is used as a foundation of an indoor partition wall material. The pore size inside the foam ceramic block is proper and distributed uniformly. The foamed ceramic block is low in preparation cost, can be prepared into various specifications according to actual use requirements, is convenient to use and has an industrialization foundation. The invention has great significance in the fields of improving the comprehensive utilization rate of solid waste, developing energy-saving building materials and the like.

2. The masonry agent of the invention uses plant extracts and industrial solid wastes as basic raw materials, has the advantages of low cost, simple process, no toxicity, environmental protection, strong binding power and the like, and is suitable for mass production. When the high-performance masonry agent is used, the extractant and the solid reinforcing agent are uniformly mixed according to the design proportion and coated on the upper surface layer of the foamed ceramic block for 1-2 mm thick and slightly pressed. Compared with materials such as traditional masonry mortar, the high-performance masonry agent does not need to be added with aggregate, and has the advantages of low cost, environmental protection, no toxicity, stable performance and the like.

Drawings

FIG. 1 is an SEM image of the interior of a ceramic foam of an embodiment of the invention, showing a pronounced cellular pore structure;

FIG. 2 is an X-ray diffraction chart of the embodiment of the invention after the mixture reaction of different types of pore-forming agents and raw materials;

figure 3 is an XRD pattern of a masonry agent in an embodiment of the present invention.

Detailed Description

The invention is further described with reference to the following detailed drawings in order to make the technical means, the creation characteristics, the achievement of the purpose and the effect of the implementation of the invention easy to understand.

Example 1

50Kg of tap water tail mud, 20kg of aluminum ash, 20kg of flue ash and 10kg of sulfuric acid residues are used as main materials, and the fineness is 100 meshes. The boron mud with 100 meshes and the 1mm castor bean powder are adopted as pore-forming agents and fillers, and the dosage is respectively 10kg and 5kg. The main material, the pore-forming agent and the filling material are uniformly mixed and 15MPa stress is adopted to form a block blank with the size of 240mm multiplied by 115mm multiplied by 53mm, and the block blank is subjected to high-temperature calcination at 1000 ℃ and cooling molding for 5 hours to prepare the environment-friendly foam ceramic block. The compressive strength, flexural strength, bulk density and thermal conductivity of the ceramic foam block were measured and the results are shown in Table 1.

Example 2

60Kg of tap water tail mud, 10kg of aluminum ash, 10kg of flue ash and 20kg of sulfuric acid residues are used as main materials, and the fineness is 150 meshes. The 50-mesh carbide slag and 1mm pine nut powder are adopted as pore-forming agents and fillers, and the dosage is 5kg and 5kg respectively. The main materials, the pore-forming agent and the filling material are uniformly mixed and 20MPa stress is adopted to form a block blank with the size of 600mm multiplied by 200mm multiplied by 240mm, and the block blank is subjected to high-temperature calcination at 1300 ℃ and cooling molding for 10 hours to prepare the environment-friendly foam ceramic block. The compressive strength, flexural strength, bulk density and thermal conductivity of the ceramic foam block were measured and the results are shown in Table 1.

Example 3

The fineness of the main materials is 200 meshes, wherein 40kg of tap water tail mud, 30kg of aluminum ash, 10kg of flue ash and 30kg of sulfuric acid residues are used as main materials. The 100-mesh industrial salt mud and 1mm spartina alterniflora leaf powder are adopted as pore-forming agents and fillers, and the dosage is 20kg and 10kg respectively. The main materials, the pore-forming agent and the filling material are uniformly mixed and 15MPa stress is adopted to form a block blank with the size of 240mm multiplied by 115mm multiplied by 53mm, and the block blank is subjected to high-temperature calcination at 1200 ℃ and cooling molding for 10 hours to prepare the environment-friendly foam ceramic block. The compressive strength, flexural strength, bulk density and thermal conductivity of the ceramic foam block were measured and the results are shown in Table 1.

Example 4

10Kg of tap water tail mud, 30kg of aluminum ash, 30kg of flue ash and 10kg of sulfuric acid residues are used as main materials, and the fineness is 300 meshes. 10kg of boron mud, 5kg of carbide slag and 5kg of industrial salt mud are adopted as pore-forming agents, and the fineness is 100 meshes. 4kg of pine nuts, 3kg of castor bean and 3kg of spartina alterniflora leaves are used as filling materials to prepare 1-3 mm powder. The main materials, the pore-forming agent and the filling material are uniformly mixed and 20MPa stress is adopted to form a block blank with the size of 600mm multiplied by 200mm multiplied by 240mm, and the block blank is subjected to high-temperature calcination at 1500 ℃ and cooling molding for 5 hours to prepare the environment-friendly foam ceramic block. The compressive strength, flexural strength, bulk density, porosity and thermal conductivity of the ceramic foam block were measured and the results are shown in table 1.

Example 5

This example differs from example 4 in that no sulfuric acid residue was added.

Example 6

This example differs from example 1 in that no boric sludge was added.

Example 7

The difference between this example and example 2 is that no carbide slag was added.

Example 8

This example differs from example 3 in that no industrial brine was added.

Example 9

This example differs from example 1 in that no castor bean is added.

Example 10

This example differs from example 2 in that no pine nut dust was added.

Example 11

The difference between this example and example 3 is that no spartina alterniflora leaf fines are added.

Comparative example 1

The 28d compression resistance, flexural strength, bulk density, porosity and thermal conductivity were measured using a class a10 autoclaved aerated concrete block with density grade B05 and dimensions 600mm×200mm×240mm as a control group, and the results are shown in table 1.

Table 1 performance parameter statistics for various embodiments

By combining the above embodiments, the compressive strength of the environment-friendly foam ceramic block is more than or equal to 78.00MPa, the flexural strength is more than or equal to 21.00MPa, the volume density is less than or equal to 260.00Kg/m ³, the porosity is more than or equal to 80.00%, and the heat conductivity coefficient is less than or equal to 0.0170W/(m.K). The foam ceramic block has excellent overall performance and is used as a foundation of an indoor partition wall material.

The invention also provides a high-performance masonry agent and a preparation method thereof in order to facilitate the normal use of the foamed ceramic block. The performance of the masonry agent will be described in detail below in connection with specific embodiments. For easy understanding, a control group is provided in this embodiment, i.e. the conventional masonry mortar M5 and M7.5 is used for performance control, and the specific cases are as follows:

example 12

Cleaning 10kg of ivy, 10kg of oleander, 10kg of buddleia, 30kg of camphor leaf, 20kg of broussonetia papyrifera leaf and 20kg of humifuse euphorbia herb, drying, putting into boiling equipment, putting into equal mass of clear water, and boiling for 10min to form an extracting solution. A solution was formed by adding 20kg of industrial alcohol to the extract. The method comprises the steps of drying and grinding 10kg of phosphogypsum, 15kg of quicklime, 35kg of steel slag and 40kg of desulfurized ash to prepare a solid reinforcing agent with the fineness of 50-200 meshes, and forming the high-performance masonry agent according to the mass ratio of extracting agent to solid reinforcing agent=7:3. The initial viscosity, initial setting and final setting times and compressive strength at different time intervals of the masonry agent were measured, and the related indexes were compared with those of the masonry mortar of M5.0 and M7.5, and the results are shown in Table 2.

Example 13

In this example, compared with example 12, the plant material ratio was adjusted to 5kg of hedera helix, 10kg of oleander, 5kg of buddleia, 20kg of camphor leaf, 30kg of broussonetia papyrifera leaf, 25kg of humifuse euphorbia herb, and the industrial alcohol consumption was 10kg. The initial viscosity, initial setting and final setting times and compressive strengths of the masonry were measured as 5kg phosphogypsum, 10kg quicklime, 55kg steel slag and 20kg desulphurized ash using the ratio of extractant: solid enhancer=7kg:3kg as the masonry, and the relevant indexes were compared with the masonry mortars of M5.0 and M7.5, the results are shown in table 2.

Example 14

In this example, compared with example 12, the plant material ratio was adjusted to 10kg of hedera helix, 5kg of oleander, 10kg of buddleia, 25kg of camphor leaf, 25kg of broussonetia papyrifera leaf, 25kg of humifuse euphorbia herb, and the industrial alcohol consumption was 10kg. The solid reinforcing agent was adjusted so that 5kg phosphogypsum, 15kg quicklime, 40kg steel slag and 50kg desulfurized fly ash were uniformly mixed to form the solid reinforcing agent. The initial viscosity, initial setting and final setting times and compressive strengths at different time periods of the masonry were determined using the extractant solid enhancer=7kg:1kg ratio as the masonry, and the relevant index was compared with the masonry mortar of M5.0 and M7.5, the results are shown in table 2.

Example 15

This example differs from example 14 in that the ratio of extractant to solid enhancing agent is adjusted to 9 kg/1 kg.

Example 16

This example differs from example 14 in that the ratio of extractant to solid enhancer is adjusted to 9kg:3kg.

Example 17

This example differs from example 12 in that no industrial alcohol was added.

TABLE 2 statistics of the major parameters of masonry agents

By combining the data provided by the embodiments, the high-performance masonry agent meets the requirements that the initial viscosity is more than or equal to 62000cps, the initial setting time is more than or equal to 45min, and the final setting time is less than or equal to 350min.12h compressive strength is more than or equal to 2.33MPa,3d compressive strength more than or equal to 3.90MPa, and 28d compressive strength more than or equal to 7.90MPa, the strength index is superior to the requirement of M7.5 masonry mortar. The high-performance masonry agent does not need to use aggregate, has the advantages of low cost, environmental protection, no toxicity, stable performance and the like, and has an industrialization basis.

FIG. 2 shows that the pore-forming agent boron mud composition contains Mg (OH) ₂ and MgSO ₄, generates a large amount of water vapor, SO ₂ and O ₂ when heated, meanwhile, the boron mud composition contains Ca (OH) ₂ and CaCO ₃, reacts with SO ₄ ^2- and the like in sulfuric acid residues to generate CaSO ₄, and the two react with heat to generate a large amount of CO ₂、SO₂ and O ₂ to help form pores, and on the other hand, the boron mud composition contains BaSO ₄, is easy to decompose to generate SO ₂ when heated, and improves the porosity of the foamed ceramic.

The carbide slag component contains a large amount of Ca (OH) ₂ and CaCO ₃, and is decomposed by heating to generate a large amount of water vapor and CO ₂, so that the porosity of the foamed ceramic is improved.

The industrial salt mud contains a large amount of CaCO ₃、Na₂CO₃ and NaHCO ₃, and is decomposed by heating to generate a large amount of water vapor and CO ₂, so that the porosity of the foamed ceramic is improved.

FIG. 3 shows that the 12H and 3d compressive strength of the masonry of the present invention is mainly achieved by the hydration reaction of phosphogypsum, quicklime and steel slag, and the gelation of lignin and cellulose binder in the plant extractant, and the hydration reaction of steel slag is gradually perfected as the age is prolonged, and other alkaline substances generated by the masonry react with active ingredients in the desulfurized ash continuously while forming a large amount of C-S-H gel, so that new aluminosilicate minerals such as ettringite, illite, clinoptilolite, etc. are generated, and new chemical binding force is further formed.

The foregoing is only the embodiments of the present invention, and therefore, the patent scope of the invention is not limited thereto, and all equivalent structures made by the description of the invention and the accompanying drawings are directly or indirectly applied to other related technical fields, which are all within the scope of the invention.

Claims

1. A foam ceramic building block, characterized in that it comprises the following raw materials in parts by weight: 100 parts of main material, 5-20 parts of pore-forming agent, and 5-10 parts of filler, wherein the main material comprises 10-70 parts of tap water tailings, 10-30 parts of aluminum ash, 10-30 parts of flue ash, and 10-30 parts of sulfuric acid slag,

The pore-forming agent is at least one of boron mud, carbide slag and industrial salt mud.

The filler is at least one of pine nuts, castor seeds, and Spartina alterniflora powder.

2. A method for preparing a foam ceramic building block according to claim 1, characterized in that it comprises the following steps:

S1. Dry and grind tap water tail mud, aluminum ash, flue ash and sulfuric acid slag to form a main material with a fineness of 100 to 300 meshes;

S2, drying and grinding at least one of the boron mud, carbide slag and industrial salt mud to form a pore-forming agent with a fineness of 50 to 100 mesh;

S3, washing at least one of pine nuts, castor seeds, and Spartina alterniflora powder, drying the powder naturally, and crushing the powder to form a filler having an average length of 1 to 3 mm;

S4, the obtained main material, pore-forming agent and filler are mixed evenly according to the designed proportion and loaded into a test mold, and a green body is formed through a stress of 15-20 MPa;

S5. calcining the prepared green body, raising the temperature to 1000-1500° C., keeping the temperature for 5-10 hours, and forming a foam ceramic building block through natural cooling.

3. A method for using the foam ceramic building blocks as claimed in claim 1, characterized in that the foam ceramic building blocks are bonded to each other using a smearing masonry agent.

4. The method of use according to claim 3 is characterized in that the masonry agent comprises the following raw materials in parts by weight: 70 to 90 parts of plant extract, 10 to 30 parts of solid enhancer, and 10 to 20 parts of industrial alcohol; the preparation method of the masonry agent is as follows: industrial alcohol is added to the plant extract to form a solution, and then mixed with the solid enhancer to obtain the masonry agent.

5. The method of use according to claim 4 is characterized in that the plant extract comprises the following raw materials in parts by weight: 5-10 parts of ivy, 5-10 parts of oleander, 5-10 parts of buddleja, 20-30 parts of camphor leaves, 20-30 parts of paper mulberry leaves, and 20-25 parts of euphorbia pulcherrima.

6. The method of use according to claim 5 is characterized in that the preparation method of the plant extract is as follows: wash, dry, chop, mix evenly, add an equal amount of water and boil to prepare an extract.

7. The method of use according to claim 6 is characterized in that the solid enhancer comprises the following raw materials in parts by weight: 5 to 10 parts of phosphogypsum, 10 to 15 parts of quicklime, 35 to 55 parts of steel slag, and 20 to 50 parts of desulfurized ash.

8. The method of use according to claim 7, characterized in that the preparation method of the solid reinforcing agent is as follows:

S1, drying and grinding the desulfurized ash and steel slag into a first powder of 50 to 100 mesh;

S2, drying and grinding the phosphogypsum and quicklime into a second powder of 100 to 200 meshes;

S3, mixing the first powder and the second powder evenly to form a solid reinforcing agent.